熱管(HEAT PIPE)設計簡介 熱管簡介熱管是利用作動流體的相變化，達到微小溫差，快速傳送大量熱量的元件，即為所謂的熱超導 1.無需外接電源 2.熱傳速率快 3.結構簡單重量輕 4.可靠性高 5.無噪音 6.無需保養維修 熱管的基本結構1.密閉容器: 鋼，鋁，銅…等2.毛細構造: 銅網，溝槽，燒結，纖維3.作動流體: 水，甲醇，丙酮….等MeshGroovePowderFiber 熱管作動原理熱管是利用作動流體的相變化產生(加熱端)，使熱立即傳輸至另一端(冷卻端)，再借由毛細結構，由冷卻端拉回加熱端並達到連續進行熱輸送QinQoutTHighTLow 熱管特性1.導熱性高2.均溫性高3.環境的適應性高4.熱流密度可變性5.熱流方向的可逆性6.高穩定性 (保證三年壽命) 熱管之應用1.電子電力機半導體元件的冷卻2. 改善熱交換器的效能3.電力電纜的冷卻4.馬達的冷卻5.高緯度地區的道路融雪6.太空船的熱控制元件PS2D/T 熱管的市場前景熱導管產品市場範圍相當廣泛，未來將是許多電子電器產品散熱必備的基本之件舉凡電源供應器、投影機、筆記型電腦、工業電腦 ,遊戲機及桌上型電腦，皆有其散熱考量之應用。
2003新產品開發計畫 熱管新產品Flatten Heat PipeThermal TowerLoop Heat PipeVapor Chamber Vapor Chamber紅外線測試 Vapor Chamber 熱反應過程12345Time: (1)08:19:18(2)08:19:24(3)08:19:30(4)08:21:45(5)08:24:35 Flatten Heat Pipe 溫差測試T1T2Theater•Theater: 60±1℃•T1: 59.6 ℃•T2: 59.8 ℃•ΔT: 0.2 ℃ 紅外線測試(一) 紅外線測試(二) Thermal Tower Thermal Tower紅外線測試 Loop Heat Pipe 紅外線測試 Time: 13:43:09Loop Heat Pipe 熱反應過程Time: 13:43:46Time: 13:46:09123 設廠地點(華南)生產基地生產基地 場地規劃 熱管產能擴線排程表27160K/M1台北華東華南華南台北台北基地1001300K/M327160K/M1404027人員111班次100K/M100K/M60K/M產能111生產線2004(Q4)2003(Q3)2002 擴線時程表 制程分析 熱管技術流程圖1. 切管製程2. 縮尾製程3. 置網製程5. 清洗製程7. 調質製程9. 真空製程4. 縮頭製程6. 焊尾製程8. 充填製程10. 加工製程11. 性能測試12. 拋光噴印切管尺寸有無毛邊縮部長度縮部外徑銅網寬度銅網長度表面光澤無斑點表面光澤有無積碳外觀變形真空度縮部長度縮部外徑無氧化焊接歪斜不油滑管身變形外觀比較充填量彎管角度壓管厚度外觀變形△T<1.2℃外觀色澤字型位置成品素材△T<1.2℃ Manufacture Process1.Cutting ProcessCutting Speed: 1420 rpm.Cutting Cycle: 150 times.Capacity: 62720 pcs/8hrs. Manufacture Process2. Shrink EndGrinding Speed: 3600 rpm.Capacity: 2880 pcs/8hrs. Manufacture Process3. Mesh InsertionInsert Pressure: 8kgf/cm²Capacity: 3150 pcs/8hrs. Manufacture Process4. Shrink NozzleShrink Pressure: 6kgf/cm²Shrink Speed: 3600rpm.Capacity: 3150 pcs/8hrs. Manufacture Process5. Clean Process7 Sinks for:(1)CH2Cl2 cleaning for 4 sinks.(2)Hot steam wash.(3)Cold steam wash.(4)Dry wash.Capacity: 18900 pcs/8hrs. Manufacture Process6. Heat TreatmentConvey Speed: 280 mm/min.Capacity: 3360 pcs/8hrs.For burning out the oxides, and reorganize the copper molecules. Manufacture Process7. Welding ProcessRotating Speed: 471 mm/sec.Capacity: 4725 pcs/8hrs. Manufacture Process8. Filling ProcessLiquid: Pure water.Capacity: 5040 pcs/8hrs. Manufacture Process9. Vacuum Process torr.Capacity: 2520 pcs/8hrs. Manufacture Process10. ReprocessPressure: 10-15 tons.Capacity: 6048 pcs/8hrs. Manufacture Process11. Performance TestAngel: +45° ~ -45°Capacity:16 pcs/8hrs. Manufacture Process12. Polish and PrintingPolish: 4835 pcs/8hrs.Printing: 9600 pcs/8hrs. Manufacture Process13. Finished Goods ψ3,4規格 ψ5,6規格 品質控制 180℃24hr(All Product)60℃ΔT Testing (All Product)Q’max Testing(Sample)Heat PipeQuality Control TestLife ReliabilityΔT TestingQ’max Test Bending ControlVariety Bending Dies for Mass Production Bending ControlAngle ControlRadius Control Electrical Conductivity Surface Roughness1. Raw Material Surface Roughness2. Semi-Finished Good Surface Roughness3. Finished Good Flatten ControlMK-1Flatten 2.5 mm Flatten ControlMK-1 Sample 1LocationABC1-0.06002-0.07-0.05-0.023-0.0200MK-1 Sample 210-0.02-0.022-0.1-0.13-0.083-0.030-0.03Sample 3 (Flatten 2.5 mm)LocationABC10-0.02-0.022-0.05-0.05-0.13-0.05-0.05-0.02Sample 4 (Flatten 2.5 mm)1-0.060-0.032-0.1-0.03-0.053-0.05-0.04-0.04 CPK FormEventFormulaEvaluate StandardTwo Ends Spec.One EndClass StandardLv.SolutionCaAccuracy(比較製程平均值與規格中心值一致的情形)Ca % = (X-μ) / (T/2)None│Ca│≦12.5%12.5% <│Ca│≦25%25% <〡Ca〡≦50%50% <〡Ca〡ABCDKeep it.Improve to A level.Revise right away.Stop process if necessary and revise over all.CpPrecision(比較製程變異寬度與規格公差範圍相差之情形)Cp = T/6ðCp=(Su-X)/3ðorCp=(X-SL)/3ð1.33≦Cp1.00≦Cp<1.330.83≦Cp<1.00Cp<0.83ABCDSame as Ca.CpkProcess Ability(總合Ca與Cp二值之指數)有兩個公式可以求得(1)Cpk = (1-|Ca|)‧CpWhen Ca = 0,Cpk = Cp(2)Cpk = Zmin/3 = Su-X/3ð or the min. of -(SL-X)/ 3ðCpk = |Cp|1.33≦Cpk1.00≦Cpk < 1.33Cpk < 1.00ABCEnough capacity.Can improve.Must improve. CPK IR Report日期(DATE) :2002/10/15品 名 (P/ Name)MK1 for IR Test製程名稱ΔΔT T客戶 (CUSTOMER)QuantaQuanta細目/SPECIFICATIONS數 值 VALUE項 目 / 單 位 / ITEM / UNITSΔT上 限 /UPPER LIMIT2.00 1~1516~3031~4546~6061~75下 限 /LOWER LIMIT0.00 1.61 標準值 /DIMENSION1.20 0.51.4 上公差 /U. TOL.0.80 1.11.5 下公差 /L. TOL.(1.20)0.60.4 統計/STATISTIC1.11.2 樣品數 /SAMPLE SIZE30 1.11.3 平均值 /AVERAGE1.047 0.70.9 標準差 /STANDARD DEV.0.305 1.31.6 最大值 /MAXIMUM1.60 11.1 最小值 /MINIMUM0.40 0.61.3 範圍 RANGE 1.20 1.21.2 ZUPPER3.127 1.10.8 ZLOWER3.434 0.81.1 CP1.094 0.91.1 CPK1.042 0.81.1 CPK IR ReportMID-CELL0.400.400.550.550.700.700.850.851.001.001.151.151.301.301.451.451.601.60FREQU.1 13 31 15 52 211113 32 22 2直 方 圖/HISTOGRAM 各式熱管加工方式頭端壓扁尾端彎角斷差圓管 熱管均溫測試•It’s the brief example of temperature difference test on heat pipes in average. 長時效性測試 熱管(ψ6x150L)傾斜角度比較θ Mesh Type 熱管(ψ6x150L)傾斜角度比較Groove Typeθ 熱管性能-長度比較ψ6ψ5Length(mm)Q’max(W)Loss(%)Length(mm)Q’max(W)Loss(%)10040W0%10035W0%15040W0%15035W0%21035W12.5%20030W14.2%27530W25%Mesh Type 熱管性能-厚度比較ψ6x150Lψ5x150LThickness(mm)Q’max(W)Loss(%)Thickness(mm)Q’max(W)Loss(%)6.0040W0%5.0035W0%3.0035W12.5%2.5025W28.5%2.5035W12.5%2.0020W42.8%2.0025W37.5%Mesh Type 熱管性能-厚度比較ψ6x150Lψ5x150LThickness(mm)Q’max(W)Loss(%)Thickness(mm)Q’max(W)Loss(%)6.0040W0%5.0035W0%3.0040W0%2.5030W14.3%2.5035W12.5%2.0015W57.2%2.0015W62.5%Groove Type 熱管紅外線溫度比對AB 模組紅外線測試 Cooler 紅外線測試 。